grabowski
ba1f5fc3a9
User, 18 Oct 2026: use an EtherCAT based system. - Spindle and conveyor on the StepperOnline A6-EC100L2A1-M17 kit (100 W, A6-200EC drive, USD 123.29), spindle through a 1:6 belt in cyclic synchronous position, conveyor in cyclic synchronous velocity. - The A6-EC drive has no divided encoder output, so an RS-422 incremental encoder on the spindle shaft clocks both line-scans; its index goes to the drive touch probe for one angle reference. - Station controller: fanless N100 mini PC with 2x Intel i226, NixOS PREEMPT_RT, EtherCAT master EtherCrab (Rust, MIT/Apache) first, IgH (nixpkgs, igc native driver on 6.12 LTS) as fallback; no PLC. - EtherCAT I/O: EK1100, EL1809, EL2809, EL3102 (warp lasers sampled with the spindle position, ~1,000 points a turn at 1 ms). - Safety stays hardwired (safety relay, contactor; no STO at 100 W). - Edge PC with the GPU stays off the real-time loop. - BOM: drives, encoder, controller and I/O lines with sources; total USD 16,112 to 32,938 (THB 0.53M to 1.09M). Next step: EtherCAT bench. - Investor render: cabinet and outfeed labels.
38 lines
4.8 KiB
CSV
38 lines
4.8 KiB
CSV
group,item,qty,example,unit_usd_low,unit_usd_high,line_usd_low,line_usd_high,source
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Frame,"40x40 slot profile, cut to length",32 m (45 pieces),"8-slot 4040 (Misumi HFS8-4040 class, or Thai/Chinese generic)",11,21,354,676,per m; Shopee Thailand listing from THB 356; aluxprofile EUR 19 to 24 per m
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Frame,"40x80 slot profile, base beams",3.8 m (2 pieces),8-slot 4080,22,42,84,160,"per m; estimate, about twice the 4040 price"
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Frame,"Cast angle brackets (24 drawn), T-nuts, screws, end caps",1 lot,,250,600,250,600,estimate
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Frame,Levelling feet M16,8,,8,25,64,200,each; estimate
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Enclosure,"Black panels, 4 mm ACM or PP, light-tight tunnel",4.3 m2,,25,60,108,258,per m2; estimate
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Enclosure,"Clear polycarbonate guard, reject zone",1.4 m2,,30,70,42,98,per m2; estimate
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Enclosure,"Door hinges, handle, safety door switch",1 lot,,120,350,120,350,estimate
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Conveyor,"PU round belt 6 mm, welded endless",2 x 3.8 m,,15,40,30,80,"each; PU round belt listings (RS, Amazon) plus welding"
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Conveyor,"Round-belt pulleys, shaft, bearings, UHMW slide strips, side guides",1 lot,,250,700,250,700,"pulleys USD 5 to 11 each (ServoCity, REV); rest estimate"
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Conveyor,"Conveyor drive: 100 W EtherCAT servo kit (same as the spindle), cyclic synchronous velocity",1,StepperOnline A6-EC100L2A1-M17,123,300,123,300,"USD 123.29 kit, China warehouse (StepperOnline, Oct 2026); high end allows for shipping, duty and a small belt reduction (estimate)"
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Handling,"Guided lift cylinder, 20 mm bore, 75 mm stroke",1,SMC MGPM20-75,330,450,330,450,SMC MGPM20-30 USD 322 (Misumi US) to 390 (Motion); 75 mm stroke a little more
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Handling,"Spindle servo kit 100 W, EtherCAT (A6-200EC drive), cyclic synchronous position; 1:6 timing belt to the spindle",1,StepperOnline A6-EC100L2A1-M17,123,300,123,300,"USD 123.29 kit, China warehouse (StepperOnline, Oct 2026); high end allows for shipping and duty (estimate)"
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Handling,"Spindle head: bearing housing, timing belt, label pad, pneumatic expanding mandrel",1,machined parts,600,1800,600,1800,estimate
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Handling,"Rodless cylinder 25 mm, 350 mm stroke, with paddle",1,SMC MY1B / CY3B class,400,900,400,900,estimate
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Handling,"Valve terminal, FRL, tubing, fittings",1 lot,,400,1000,400,1000,estimate
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Vision,"4k monochrome line-scan camera, GigE",2,Basler racer 2 r2L4096 / Hikrobot MV-CL042-91GM,857,1088,1714,2176,Basler web shop via price listing
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Vision,"Line-scan lens, 50 mm",2,,300,800,600,1600,estimate
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Vision,Coaxial line light,2,,295,446,590,892,made-in-china listing USD 295 to 349; Vision Datum USD 420; light186 from USD 446
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Vision,"Dark-field line light, about 150 mm",4,Vision Datum LiN+ class,250,400,1000,1600,Vision Datum LiN+ USD 380
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Vision,Diffuse line backlight,2,,200,400,400,800,estimate
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Vision,"Colour area camera, 8 MP, GigE",2,Basler ace 2 a2A2840-14gcPRO,1119,1119,2238,2238,Basler web shop via price listing
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Vision,Lens 16 mm,2,,150,400,300,800,estimate
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Vision,Ring light,2,,150,400,300,800,estimate
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Vision,Strobe and light controllers,2,,300,800,600,1600,estimate
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Sensors,"Laser distance sensor, 50 mm range",2,Micro-Epsilon optoNCDT 1420,520,1600,1040,3200,"list from EUR 470 (Micro-Epsilon); ILD1420-25 about USD 1,600 (Radwell)"
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Sensors,Photoelectric presence sensors and one through-beam,5,,50,150,250,750,each; estimate
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Sensors,"Cylinder position switches (lift up/down, pusher home/out, mandrel open/clamped)",6,SMC D-M9 class,25,60,150,360,each; estimate
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Sensors,"Spindle incremental encoder, RS-422 line driver, 2,500 to 5,000 pulses a turn: A/B clock both line-scans, index to the servo touch probe",1,Omron E6B2-CWZ1X class,60,300,60,300,estimate
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Sensors,"Thermal camera (option, not in the total)",0 (1 optional),Optris Xi 400,2100,3000,0,0,"from EUR 1,950 (Optris); USD 2,995 (moviTHERM)"
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Control,"EtherCAT station controller: fanless mini PC, Intel N100 class, 2x Intel i226, NixOS with PREEMPT_RT, open-source EtherCAT master (EtherCrab or IgH)",1,Topton / CWWK N100 2x i226 class,162,470,162,470,"from USD 162 (Alibaba listing) to 279 to 469 at retail (plugpcs.com, Newegg), Oct 2026"
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Control,"EtherCAT I/O: EK1100 coupler, EL1809 16 DI, EL2809 16 DO, EL3102 2 AI (warp lasers), end terminal",1 set,Beckhoff,430,780,430,780,EK1100 USD 131 (industrialsupplygroups); EL1809 EUR 78 net (industry-electronics); EL2809 USD 99 net (TME); EL3102 EUR 111 (automation-base) to USD 290 (plcpartssolution); Oct 2026
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Control,"Edge PC with GPU, 4 GigE PoE ports, NixOS",1,,1500,3200,1500,3200,"qscompute buying guides 2026: USD 1,490 to 3,200"
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Control,"HMI touch panel, 10 inch, showing the station's browser page",1,,400,900,400,900,estimate
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Control,"Safety relay, e-stop, door interlock wiring, contactor in the drive supply (the 100 W kit has no STO)",1 lot,,300,600,300,600,estimate
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Control,"Cabinet, power supply, breakers, terminals, wiring, stack light",1 lot,,800,2000,800,2000,estimate
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Total,"Hardware per station, thermal camera excluded",,,,,16112,32938,sum of the lines above
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